Building panels and building system using such panels

ABSTRACT

A wall panel system has at least one panel with face sheets of compressed solid cement or gypsum based material bonded to a foam core. The core has at least one channel extending through the core on an axis along the length of the panel from a predetermined position on a top edge to a bottom edge of the panel. A slot is provided on opposed side/end edges of the core to allow for a strengthening rod to be inserted between adjacent panels. An edge recess extends along one or more edges of the panel between the rear of the face sheet(s) and the core. The recess can receive and discretely hide connecting panel/plate members connecting adjacent panels.

FIELD OF THE INVENTION

The present invention relates to building panels and a building systemusing such building panels, such as those used for low cost housing andcommercial properties.

BACKGROUND TO THE INVENTION

There is a need for low cost structures, such as residential andemployee housing as well as commercial and industrial properties.

Traditional brick and concrete blocks are energy intensive tomanufacture. Constructing a building using bricks or blocks is also timeconsuming and labour intensive, requiring brick layers to lay thebricks/blocks using mortar.

Thermal panels are known and can be used as an alternative form ofbuilding construction. Thermal panels are typically used for cold storesbecause of their high thermal insulation properties, but are also usedto clad buildings for the same reason.

Thermal panels typically have a sandwich construction of outer sheets oftimber, gypsum or anti-corrosion coated steel, bonded either side of asheet of material of low coefficient of thermal conductivity, typicallyfoam, such as expanded polystyrene.

One benefit of using panels is that they can be packed flat together andtransported with minimal loss of space. Fast building construction isachieved by mounting the panels to a metal or wooden skeletal frameworkto erect the building. That is, the panels are typically used to clad aframework.

Such thermal panels are generally supplied in set sizes. Cutting panelsto size on site is achievable if simple square ended butt joints areacceptable. However, such butt joints, especially at corners of wallslack strength and rigidity. An improved concept is required wherebypanels can be produced that form improved corners, both for accuracy andrigidity.

Also, it would be beneficial to tie the top of the panels to the floorfor improved structural integrity of the building, particularly incyclone rated environments.

With this in mind, it has been found desirable to provide wall panelswith improved features to aid construction of a building.

It is also desirable to provide a wall panel building system withimproved structural integrity.

It is further considered desirable to provide a wall panel arrangementwhereby corners of building or walls can be constructed more accuratelyand with greater rigidity from flat building panels.

SUMMARY OF THE INVENTION

With the aforementioned in view, an aspect of the present inventionprovides a wall panel comprising at least one material with dimensionsof length, width and thickness defining the panel, the panel havingfirst and second opposed external panel faces, the length and widthbeing substantially greater than the thickness, the wall panel includingat least one aperture extending within the material on an axis along thelength of the panel from a predetermined position on an end face of thepanel determined by said width and thickness.

Preferably the at least one aperture is a single aperture extendingthrough the panel from one end face to an opposite end face defined bythe width and thickness.

The axis preferably extends centrally from the end face(s) i.e. halfwayacross the thickness and width.

The at least one aperture may be a rectilinear shape in cross section,preferably square. However, circular or other shapes are envisaged tofall within the scope of the present invention.

The aperture extending into the material at the end face provides acutting marker. However, an additional linear or other mark onto or intothe surface of the end face(s) may be provided. For example, a (ink)scribed, printed or inscribed mark on the surface as a linear indicatordiagonally across the aperture may be provided. Such linear markers may,if imaginarily extended, extend externally away from the opposed facesof the panel.

First and second panel portions are formed once the panel is cut throughalong its length following the at least one aperture. With the cut madethrough the material along the axis at an acute/obtuse angle withrespect to the first and second faces, each resulting panel portion hasa channel in an oblique edge face thereof formed by the cutting alongthe length of the panel. With one of the panel portions reversed, theoblique edge faces form a mitred corner with a corner central channeltherethrough from one end face to the other.

A connecting member can be inserted through the corner central channelto tie a top plate and a floor plate of a building system. Thisconnecting member ensures the roof is tied down to the floor, which isparticularly useful in high wind/cyclone regions. The connecting membermay be a metal rod connected to a top plate and bottom plate member,such as by screw fastening, nut and bolt or welding etc.

A structural member may alternatively or additionally be insertedthrough the corner central channel to provide structural integrity tothe building. Preferably the structural member may include an elongatesteel member, preferably of steel (which may be galvanised or stainlesssteel). The structural member may be between 10 mm and 150 mm wide by 10mm to 150 mm thick and approximately between about 1200 mm long to about3600 mm long.

An internal strengthener may be applied to the mitred corner. Preferablythe internal strengthener is positioned in the recess at the respectiveexterior or interior angle of the corner between the respective facingsheet and the core. The strengthener may include an elongate anglemember, such as ‘L’ (uneven length arms) or ‘V’ (even length arms) incross section to cover, protect and strengthen the corner. Thestrengthener may be bonded to the core and/or facing sheet by anadhesive and/or screw fastener(s).

The panel may include an external channel extending along the length ofone or both edges of the panel between the end faces. Each such externalchannel may be half the cross section of said at least one aperturethrough the material. This, if one panel is cut along its length throughthe at least one aperture and perpendicular to the first and secondpanel faces, the resulting panel portions will have channels with crosssection corresponding to the edge channels along the external edges ofthe panel.

The first and/or second face of the panel may include a recess adjacenta peripheral edge thereof. For example, a recess of a few millimetresdepth into the panel face may be provided long a peripheral edge portionof the respective first or second face such that a correspondingadjacent panel with a similar recess creates a recessed region for aconnecting plate. The recess may preferably be between 20 and 50 mm wideand between 2 mm and 5 mm depth. Preferably the recess is between 35 and40 mm wide and between 2.0 mm to 5 mm deep, and more preferably 37 mmwide and 2.0 mm deep.

Thus, the connecting plate can cover the join between two adjacentpanels and, with the connecting plate a matching thickness to the depthof the adjacent recesses, may create a continuous facing surface acrossthe two adjacent panels.

At corners, the external facing surfaces of two panels meeting at anangle to one another may have the recesses adjoining such that a cornerconnecting member creates a continuous exterior surface at the corner.

The recess may be provided on a face of the panel(s) on an interior ofthe room/building. Thus, a continuous surface can also be created on theinside of the room/building.

Internal connecting plates (internal of the panel between the core andfacing sheet) may be joined though the thickness of the core.

A said panel may include one or multiple apertures through the corematerial from one end edge to the opposite end edge. Thus, one panel caneither be cut down along one or both of the apertures to create panelportions, or the single large panel can be used to span a wide wallspace. For example, a single panel may be 2400 mm, 2700 mm or 3000 mmhigh, and 1200 mm wide, each with a respective aperture centre at 400 mmcentres on the end faces and inboard from a respective longitudinal sideedge.

The panel may have a sandwich construction, with a core of a thermalinsulation material and external first and second faces formed of sheetmaterial. The insulation material may be a foam material, preferablyexpanded polystyrene. The panel face material may be of gypsum and/orcement based material.

The sheet facing material may be bonded to the core by adhesive. Thesheet facing material may extend over the peripheral recess around theedges of the face of each sheet of core material. Thus, joiners betweenadjacent sheets set into the recess across adjoining sheets may behidden behind the facing sheet material which creates a continuousexternal surface.

Multiple building panels may be used to form a doorway or windowopening. For example, two of the panels may be provided spaced apart tocreate a door or window opening width, and one or more similar panelsprovided extending over the top of the opening to create the doorway orwindow opening.

The building system according to a further aspect of the presentinvention may include multiple building panels. The system may includeconnection means connecting a top plate to a floor structure or floorplate. For example, the aperture channel extending vertically betweenadjacent panels may have a rod inserted therein, the rod connected to atop fixing and lower fixing. The rod ties the top plate to the floor,which can preferably assist in cyclone proofing the building, especiallythe roof by assisting in tying the roof through to the floor.

The floor may include a surround around a concrete base. The surroundmay be of plastic or metal material. Plastic is beneficial because it isnon-corrosive. The surround is known as a perimeter channel and itprovides form work for the pouring of the concrete floor (slab). Oncethe concrete is set, the perimeter channel may not be removable from theconcrete floor.

At 600 mm centres, holes are provided in the floor to insert 45 degree200 mm crank bolts which in turn are engulfed by the concrete as it ispoured. When the concrete is set, these bolts anchor a coupler bolt andtie down rod at each point around the floor. Thus, the roof is tied tothe floor via the tie down rods passing through the panels and boltedinto the concrete floor.

The metal or plastic perimeter channel may include a respective steel orplastic beam structure creating a floor perimeter arrangement. Therod(s) may connect to the beam structure, though preferably are fixedinto the concrete floor via anchor bolts set into the concrete.

When the perimeter channel arrangement is used, a rubber or rubberisedseal may be provided between the perimeter channel and the bottom plate.If no perimeter channel is used, the rubber or rubberised seal may beprovided between the concrete floor and bottom plate.

Chemical anchors may be provided in the concrete floor wherever aconnection to one of the rods is required. This is preferably eitherevery 600 mm or 1200 mm into the concrete to hold the tie down rods.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will hereinafter be described withreference to the accompanying drawings, in which:

FIGS. 1 a and 1 b show a building panel according to an embodiment ofthe present invention.

FIGS. 2 a and 2 b show a building panel according to an embodiment ofthe present invention.

FIGS. 3 a and 3 b show a building panel according to an embodiment ofthe present invention.

FIGS. 4 a and 4 b show a building panel according to an embodiment ofthe present invention.

FIGS. 5 a and 5 b show a building panel according to an embodiment ofthe present invention.

FIGS. 6 a and 6 b show a building panel according to an embodiment ofthe present invention.

FIGS. 7 a and 7 b show a building panel according to an embodiment ofthe present invention.

FIGS. 8 a and 8 b show a kitchen building panel according to anembodiment of the present invention.

FIG. 9 shows a building panel arrangement for a doorway according to anembodiment of the present invention.

FIGS. 10 and 11 show installation arrangements for a building systemincorporating panels according to an embodiment of the presentinvention.

FIG. 12 shows a corner arrangement with two mitre edge panels forming anaperture channel therebetween and having a strengthener plate over theexternal corner edge.

FIG. 13 shows an end on view of a panel according to an embodiment ofthe present invention including a longitudinal recess to receive alintel, such as over a window, door or garage opening.

FIGS. 14 to 16 show top/bottom end views of a panel according toalternative embodiments of the present invention.

DESCRIPTION OF PREFERRED EMBODIMENT

FIGS. 1 a through 8 b show alternative building panels according toembodiments of the present invention.

FIGS. 1 a and 1 b show a building panel 10 with first 12 and second 14facing sheets of a compressed, solid cement based material. Othermaterials, such as a gypsum based material, can be used. The core 16 isof expanded polystyrene. The facing sheets are bonded to the core usingan adhesive.

FIGS. 1 a and 1 b show the recess 26 formed in the core material suchthat, when the facing sheets are applied, a narrow channel is created.This channel can hide a connecting panel/plate between adjacent panels.

A slot 18,20 is provided on the opposed side edges of the panel 10. Whenthese slots abut to corresponding slots on adjacent panels, a channel isformed to receive a support member, such as a steel rod extending thelength of the panels. Such a support member can be tied to a floor and atop plate to add structural strength and rigidity to a building systemincorporating the panels.

FIGS. 2 a and 2 b show a central channel 22 extending through theinterior length of the panel from a top edge 30 to a bottom edge 32.This central channel 22 can also receive a support member as used in theabutted edge slots.

The edge recess 26 can extend along a central portion 28 of the panel.This is preferably twice the width of the edge recess 26. Thus, when thepanel is cut in half, the double width recess forms two recesses of thesame width as the edge recesses 26.

Also, when the panel is cut through along the a central axis, the cutpasses centrally through the rectilinear channel 22 to form two slotsequivalent to the edge slots 18,20.

It will be appreciated that the central channel can be of any desiredcross sectional shape, though regular shapes are preferred. For example,circular, square or diamond shapes.

FIGS. 3 a and 3 b show an alternative embodiment of a building panel ofthe present invention, with a diamond shaped central channel 24. In suchan embodiment, when the panel is cut through at a 45° angle (lines A-Aor B-B) with respect to the plane of the building panel, a mitred edgeface is formed with a square U cross section slot is formed in eachhalf. Thus, the two panel halves can be used for a mitred 90° corner.With the central recess sufficiently wide, new edge recesses are formed.

FIGS. 4 a and 4 b show an alternative form of the building panel 10 ofthe present invention. This is a wider panel with two aperture channels22 a, 22 b running through the core offset from the centreline C-C.However, the concept of being able to cut the full panel down throughthe channels 22 a, 22 b to form narrower panel sizes and still retainthe edge slot feature. Likewise the central recess 28 in FIG. 3 bbecomes a pair of offset recesses 28 a, 28 b in this panel. Otheriterations using this same concept are envisaged to fall within thescope of the present invention.

FIGS. 5 a and 5 b show a building panel 10 with facing sheets 12 and 14and core 16 as described previously. The central aperture channel 24 isdiamond in cross section and extends through the length of the corebetween the top 30 and bottom 32 end faces.

When cut diagonally e.g. at 45° to normal to the facing sheets, a pairof mitred sub-panels 10 a, 10 b are formed. These have the square Ushaped slot running along the newly formed side edge of each sub-panel.

In the alternative, FIGS. 6 a and 6 b show a preformed mitred edge panelthat does not need cutting to form the mitre. Such a panel can besupplied to site preformed from the factory to meet a planned designrather than needing cutting onsite. It will be appreciated that such apanel can be formed from a larger panel as in FIGS. 5 a, 5 b, but in thefactory to save material.

FIGS. 7 a and 7 b show a building panel 10 of the present invention withmitred edges 40, 42 along each side edge. Thus, such a panel can bepreformed in the factory and transported to site without the need forcutting onsite.

The panel in FIGS. 8 a and 8 b is designed for kitchens and/orbathrooms, whereby kitchen cabinets or bathroom cabinets respectivelycan be mounted to the panel. A steel plate 44 can be retained in therecess 46 between the core material 16 and facing sheet 12,14. Thus,cabinets, which are relatively heavy (especially when loaded with items)is supported by fastenings through the panel into the steel plate.Preferably the steel plate is galvanised.

FIG. 9 shows a doorway construction using three panels of the presentinvention. The doorway has two upright panels 10 a, 10 b and a headerpanel 10 c extending over them. Window openings can be formed the sameway.

FIG. 10 shows a building system arrangement 60 with a square U channelsection floor plate 62 bolted to a steel floor beam 64 that surrounds aconcrete floor 66. The channel forms a bottom plate and is bolted intothe concrete floor using a bolt system 68. The upright portions 70 ofthe bottom channel slot into the recesses 26 behind the facing sheets12,14 of the panel 10 to create a smooth continuous surface with hiddenconnections.

A tie rod 72 passes through the aperture channel 74 through the panel.The tie rod is fastened to a fixing plate 76 via a fastening nut 78 toattach the tie rod to the top plate 80. The fixing plate also attachesto a roof beam 86. The top plate has elongate side portions similar tothe bottom plate portions 70, but these do not need to be concealed inthe recesses 26 because they are either hidden behind cornice 82 or areat facia board level externally.

In an alternative embodiment shown in FIG. 11, the building panel 10slots into a top channel 80 and bottom channel 62. The bottom channel isfastened directly into the concrete floor 66. The top channel is fixeddirectly to the ceiling beam 90.

FIG. 12 shows a mitred corner using two mitred corner panels 10 d, 10 eforming a corner aperture channel 50 for a tie rod strengthener memberand having a corner strengthener 48 within the recess 26.

FIGS. 13 to 16 show alternative forms of panels according to embodimentsof the present invention.

FIG. 13 shows a lintel panel 100. The panel 100 includes sheet facings12 and 14 similar to the embodiments described above. One longitudinalside edge 102 includes a full length recess or channel 104 to receiveand cover a lintel (not shown). The recess or channel has a depth E intothe panel of preferably 200 mm and a width F preferably of 100 mm,though other dimensions fall within the scope of the present inventionto suit the particular application of the panel. It will be appreciatedthat the lintel recess arrangement can have a recess of largerdimensions, such as 190 mm wide by 90 mm deep, or other dimensions tosuit a required application. The lintel recess can be within the corebounded on three sides by core material, or can be exposed to the endedge and to one side i.e. bounded by core material on only two sides.

FIG. 14 shows a top/bottom end/edge view of an alternative an embodimentof the panel 200. The panel 200 has an enlarged recess/channel 202 inone side edge. The recess/channel is preferably of 90 mm depth G and 90mm width H, though it will be appreciated that other depths and widthscan be accommodated depending on the required application.

The extra width and depth compared with the recess/channel 18,20previously described allows the panel edge to accommodate largerstructural supports, such as 90/90 mm steel or timber posts, or allowroom for smaller dimensioned posts and electrical and/or plumbingutilities.

Inset from the edge recess 18,20 is at least one passage passing throughthe core 16 form the top edge to the bottom edge. Preferably thispassage is oval in cross-section, though other shapes are permitted. Ina preferred form, the cross section is an oval of around 50 mm length by30 mm width.

The passage can accommodate electrical and plumbing utilities. In apreferred arrangement, the passage is inset from the edge of the panelby 150 mm, which passage can therefore be utilised close to the edge ofthe panel, for connection of electric light switches to the electricalcable positioned close to the edge of walls and doors etc., but insetsufficiently from the panel edge to allow for door frames and wallcorners and still allow for panel strength at the panel edge.

FIG. 15 shows a version of the panel 200 with two of the larger edgerecesses 202, one recess/channel 202 a, 202 b at each opposed edge.

FIG. 16 shows a further preferred embodiment of the panel 200 with ovalutility passageways 204 through the core as described in relation toFIG. 14. These are preferably inset with their respective centres 150 mmfrom the edge of the panel, as indicated at J in FIG. 16. These allowthe passages to be predictably found for running utilities after thepanel system has been erected. A central channel 206 passes through thecentre of the core 16.

Preferably each oval passageway has dimensions 50 mm (K) by 30 mm (L) asshown in FIG. 16, though other dimensions can be selected within thecore of the panel as required for a particular application.

It will be appreciated that the oval cross section passageways can besquare in cross section or diamond or other regular polygon to suit anapplication of the panels.

1. A wall panel comprising at least one material with dimensions of alength, a width and a thickness defining the panel, the panel having afirst face and a second face forming opposed external panel faces, thelength and width being substantially greater than the thickness, thewidth and thickness define two opposite end faces, two opposite edgesare located between the two opposite end faces, the wall panelcomprising at least one aperture extending within the at least onematerial on an axis along the length of the panel from a predeterminedposition on one end face of the panel determined by said width andthickness.
 2. The panel according to claim 1, wherein the at least oneaperture is a single aperture extending through the panel from one endface to an the opposite end face defined by the width and thickness. 3.The panel according to claim 1, wherein the axis extends centrally fromthe end face(s).
 4. The panel according to claim 1, the at least oneaperture being of regular cross sectional shape or having a crosssection of rectilinear shape.
 5. (canceled)
 6. The panel according toclaim 1, comprising an indicator mark or a plurality of indicator marksonto or into a surface of the respective end face(s).
 7. The panelaccording to claim 6, the indicator mark(s) being scribed, written,printed or inscribed on the surface as a linear indicator diagonallyacross the aperture.
 8. The panel according to claim 1, wherein a firstpanel portion and a second panel portion are formed once the panel iscut through along its length following the at least one aperture.
 9. Thepanel according to claim 8, wherein the cut made through the at leastone material along the axis is at an acute or obtuse angle with respectto the first and second faces, each resulting panel portion has achannel in an oblique edge face thereof formed by the cutting along thelength of the panel.
 10. The panel according to claim 9, forming acorner panel with one of the panel portions reversed, the oblique edgefaces forming a mitred corner with a corner central channel therethroughfrom one end face to the other.
 11. The panel according to claim 1,comprising an external channel extending along the length of one or bothedges of the panel between the end faces.
 12. The panel according toclaim 11, each external channel being half the cross section of said atleast one aperture through the at least one material.
 13. The panelaccording to claim 1, the first and/or second face of the panelcomprising a respective recess adjacent a peripheral edge thereof. 14.The panel according to claim 13, wherein the recess is between 20 and 50mm wide and between 2 mm and 5 mm deep.
 15. The panel according to claim1, comprising one or multiple apertures through a core material from oneedge to the opposite edge.
 16. The panel according to claim 1, having asandwich construction, with a core of a thermal insulation material andthe first and second faces formed of sheet material.
 17. The panelaccording to claim 16, the insulation material comprising a foammaterial.
 18. The panel according to claim 1, further comprising a core,wherein the first and second faces are formed of a sheet material, andare bonded to the core by adhesive.
 19. The panel according to claim 1,further comprising sheets of a core material, wherein the first andsecond faces are formed of a sheet material extending over a peripheralrecess around the edges of the face of each sheet of the core material.20. A building system comprising multiple panels according to claim 1,and connection means to retain adjacent panels together.
 21. A buildingsystem according to claim 20, the connection means connecting a topplate to a floor structure or a floor plate.
 22. A building systemaccording to claim 20, the comprising an aperture channel extendingvertically between adjacent panels and a rod received therein, the rodconnected to a top fixing and a lower fixing.
 23. A building systemaccording to claim 20, the panels supported by a floor, the floorcomprises a metal surround around a concrete base.
 24. The buildingsystem according to claim 20, comprising a connecting member insertedthrough a corner central channel to tie a top plate and a floor plate ofa building system together.
 25. The building system according to claim20, the connecting means comprising a metal rod connected to a top platemember and a bottom plate member by screw fastening, nut and bolt orwelding.
 26. The building system according to claim 20, comprising aninternal strengthener within the panel at an external corner.
 27. Thebuilding system according to claim 26, comprising external opposingfacing sheets, wherein the strengthener comprises an elongate anglemember with an ‘L’ in cross section between the respective facingsheet(s) and a core material.
 28. The building system according to claim20, comprising multiple said panels forming a doorway or a windowopening.